Safety Helmet

Abstract

A protection system including a safety helmet or hard hat, an impact protection layer, and a suspension system is shown. The hard hat includes an impact protection layer and a suspension system coupled to an interior surface of the hard hat. Various suspension mechanisms and strap systems for hard hats are described herein.

Claims

1. A protective helmet comprising: an outer shell formed from a rigid material, the outer shell comprising: an exterior surface; and an interior surface that defines a cavity; an impact protection layer coupled to the interior surface; a protrusion extending inward from the interior surface of the outer shell; and a suspension system coupled to the outer shell, the suspension system comprising: a headband portion positioned in the cavity and extending along a portion of a circumference of the outer shell; and a post extending from the headband portion, the post comprising an aperture; wherein the protrusion extends through the aperture and resists movement of the suspension system away from the interior surface.

2. The protective helmet of claim 1, wherein the aperture of the post comprises: a first recessed portion; a second recessed portion; a center portion positioned between the first recessed portion and the second recessed portion.

3. The protective helmet of claim 1, wherein the protrusion comprises: a body extending outward from the interior surface of the outer shell; and a ledge extending downward, toward a bottom segment of the outer shell.

4. The protective helmet of claim 3, wherein the ledge engages the post to resist movement of the suspension system away from the interior surface.

5. The protective helmet of claim 3, wherein the bottom segment defines a lower circumference of the outer shell.

6. The protective helmet of claim 1, wherein the protrusion is accessible and uncovered by the impact protection layer.

7. The protective helmet of claim 1, wherein the impact protection layer further comprises a recessed section, and wherein the protrusion is positioned within the recessed section of the impact protection layer.

8. The protective helmet of claim 1, further comprising a strap system coupled to the suspension system, the strap system configured to couple the protective helmet to a user.

9. A hard hat comprising: an outer shell formed from a rigid material, the outer shell comprising: an exterior surface; and an interior surface that defines a cavity; an impact protection layer coupled to the interior surface; a protrusion extending inward from the interior surface of the outer shell, the protrusion spaced from the impact protection layer; and a suspension system coupled to the outer shell, the suspension system comprising: a headband portion positioned in the cavity and extending along a portion of a circumference of the outer shell; and a post comprising an aperture, wherein the protrusion extends through the aperture.

10. The hard hat of claim 9, wherein an inward facing surface of the protrusion is a continuous surface.

11. The hard hat of claim 10, wherein the inward facing surface defines an innermost portion of the protrusion.

12. The hard hat of claim 9, wherein the aperture of the post comprises: one or more recessed portions; and a center portion, wherein the center portion and one or more recessed portions together define a perimeter of the aperture.

13. The hard hat of claim 9, wherein the protrusion further comprises: a body extending away from the interior surface of the outer shell; and a ledge extending toward a lower circumference of the outer shell.

14. The hard hat of claim 13, wherein, when the ledge engages the post, the ledge resists movement of the suspension system away from the interior surface.

15. The hard hat of claim 9, wherein the suspension system further comprises a second post extending from the headband portion, the second post comprising a second aperture configured to receive a second protrusion.

16. A hard hat comprising: an outer shell formed from a rigid material, the outer shell comprising: an exterior surface; an interior surface that defines a cavity; a crown configured to cover a head of a wearer; and a bottom segment defining a lower circumference; a protrusion extending inward from the interior surface of the outer shell, the protrusion comprising: a body extending away from the interior surface of the outer shell; and a ledge extending toward the bottom segment of the outer shell; and a suspension system coupled to the outer shell, the suspension system comprising: a headband portion positioned in the cavity and extending along a portion of a circumference of the outer shell; and a post comprising an aperture, wherein the protrusion extends through the aperture.

17. The hard hat of claim 16, wherein the ledge overhangs a portion of the post of the suspension system.

18. The hard hat of claim 16, wherein the ledge extends beyond a lowermost portion of the body.

19. The hard hat of claim 16, further comprising an impact protection layer coupled to the interior surface, wherein the protrusion is uncovered by the impact protection layer.

20. The hard hat of claim 19, wherein the impact protection layer comprises a recessed section, and wherein the protrusion is positioned within the recessed section.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

[0011] FIG. 1 is a perspective view from above of a safety helmet, according to an exemplary embodiment.

[0012] FIG. 2 is a perspective view from below of a portion of an outer shell and impact protection layer of FIG. 1 disconnected from a suspension system, according to an exemplary embodiment.

[0013] FIG. 3 is a detailed perspective view of FIG. 2, according to an exemplary embodiment.

[0014] FIG. 4 is a perspective view from below of a coupler of the safety helmet, according to an exemplary embodiment.

[0015] FIG. 5 is a side view of the coupler of FIG. 4, according to an exemplary embodiment.

[0016] FIG. 6 is a perspective view from below of a portion of an outer shell and impact protection layer of FIG. 1 connected to the suspension system, according to an exemplary embodiment.

[0017] FIG. 7 is a detailed perspective view of FIG. 6, according to an exemplary embodiment.

[0018] FIG. 8 is a removal tool, according to an exemplary embodiment.

[0019] FIG. 9 is a perspective view from below of a portion of an outer shell and impact protection layer connected to the suspension system and the removal tool, according to an exemplary embodiment.

[0020] FIG. 10 is a perspective view of the removal tool engaged with the suspension system of, according to an exemplary embodiment.

[0021] FIG. 11 is a detailed perspective view of a portion of a suspension system, according to another exemplary embodiment.

[0022] FIG. 12 is a perspective view of the suspension system of FIG. 11 coupled to an outer shell of a safety helmet, according to an exemplary embodiment.

[0023] FIG. 13 is a detailed perspective view of a portion of a suspension system, according to another exemplary embodiment.

DETAILED DESCRIPTION

[0024] Referring generally to the figures, various embodiments of a safety helmet or hard hat system are shown. As will be generally understood, safety helmet or hard hat systems are worn by users during activities where the user is frequently moving. Applicant has developed various improvements to the attachment between the suspension system and hard hat to securely and comfortably couple hard hats to the user's head even while the user works, moves around, etc.

[0025] For example, compared to conventional safety helmet attachments that may require permanent couplers such as screws, the safety helmet systems discussed herein allow for secure attachment between the hard hat and suspension system without using couplers such as screws that may make replacing the suspension system difficult. In contrast, in various embodiments discussed herein, the suspension system uses a snap fit system to couple to the hard hat. In various specific embodiments, the suspension includes one or more tabs including apertures configured to couple to projections located on the interior surface of the hard hat. Applicant has found the use of the snap fit system allows for secure attachment between the hard hat and suspension while also allowing for easy removal. As such, the suspension system can be quickly and easily replaced by the user.

[0026] In various specific embodiments, the suspension is removable from the hard hat using a hand tool such as a pick. In various specific embodiments, the suspension is removable from the hard hat using a 90 degree pick.

[0027] Referring to FIG. 1, a perspective view of a protective work or construction helmet system, shown as hard hat system 10, is shown according to an exemplary embodiment. Hard hat system 10 includes a hard hat 12 having an outer shell 20 and a suspension system 14. In a specific embodiment, outer shell 20 is formed from a rigid material, such as a rigid polymer material. In various specific embodiments, outer shell 20 is formed from one of high-density polyethylene (HDPE), acrylonitrile-butadine-styrene (ABS), polycarbonate (PC), polycarbonate/acrylonitrile-butadine-styrene (PC-ABS), and polypropylene (PP). Outer shell 20 includes an exterior surface 28 and an interior surface 36 (see e.g., FIG. 2).

[0028] Outer shell 20 includes a crown 21 and a bottom segment 27. In various embodiments, crown portion 21 is configured to cover a head of the user/wearer. In specific embodiments, bottom segment 27 defines a lower circumference of hard hat 10.

[0029] Hard hat system 10 includes the suspension system 14 to support and secure hard hat 12 to a wearer's head. In various embodiments, suspension system 14 includes a headband portion 17 that extends around at least a portion of a circumference of hard hat 12. Straps, shown as chin straps 15 extend from the headband portion 17 to secure hard hat system 10 around a user's chin and/or face. In specific embodiments, suspension system 14 includes a ratcheting mechanism to adjust a size of the suspension system to the user's head.

[0030] Outer shell 20 further includes a plurality of apertures or vents 22. Vents 22 extend through outer shell 20 providing fluid communication between a cavity 25 defined by interior surface 36 and the ambient air proximate to exterior surface 28 of outer shell 20. Outer shell 20 further includes recess 26 positioned between a front 16 and rear 18 of hard hat 12 proximate to the ears of wearer. In a specific embodiment, recess 26 extends a height above a portion of a bottom segment 27 of hard hat 12 proximate to front 16 and/or rear 18 of hard hat 12. In various specific embodiments, a brim 24 projections outward from outer shell 20 at front 16 of hard hat 12.

[0031] Hard hat 12 further includes a mounting ridge 30 positioned on the front 16 of outer shell 20. Mounting ridge 30 includes a first or right edge 31 protruding outwardly from the mounting ridge 30 and a second or left edge 33 opposing the right edge 31 and protruding outwardly from the mounting ridge 30. In a specific embodiment, mounting ridge 30 includes a detent positioned between the right edge 31 and the left edge 33 and configured to interface with an accessory mounting bracket 56 and/or an accessory. The right edge 31 and left edge 33 of the mounting ridge 30 each extend toward the bottom segment 27 of the outer shell 20. The right edge 31 and left edge 33 each include a portion with an increased width as the right edge 31 and left edge 33 approach the bottom segment 27 and/or the brim 24.

[0032] Various embodiments of hard hat 12 include one or more mounting ridges configured to couple to and/or support hard hat accessories. A side accessory support ridge or auxiliary mounting ridge 32 is coupled to a lateral side of outer shell 20 along the bottom segment 27. Auxiliary mounting ridge 32 includes a first end and a second end opposing the first end. A plurality of apertures or slots 34 are positioned along auxiliary mounting ridge 32 between the first end and the second end. In a specific embodiment, auxiliary mounting ridge 32 includes three slots 34. In various embodiments, an additional side accessory support ridge or auxiliary mounting ridge 32 is coupled to an opposing lateral side of outer shell 20 along the bottom segment 27. Auxiliary mounting ridge 32 supports accessories for hard hat 12, such as earmuffs, tool or eyeglass holders, lamp supports, face shields, and/or reflectors, etc. In a specific embodiment, a clip 58 is couplable to hard hat 12 and can be positioned within a slot 34 such that accessories are supported from auxiliary mounting ridge 32.

[0033] Referring to FIGS. 2-3, details of the attachment mechanism between suspension system 14 and hard hat 12 are shown according to an exemplary embodiment. Hard hat system 10 further includes an impact protection layer 38. In various specific embodiments, impact protection layer 38 is formed from an impact absorbing material. In various specific embodiments, impact protection layer 38 is formed from a foam material. Impact protection layer 38 includes a plurality of openings 39 (see e.g., FIG. 4). When impact protection layer 38 is coupled to outer shell 20, openings 39 allow for fluid communication between cavity 25 and the ambient air proximate to exterior surface 28 due to communication between one or more vents 22 of hard hat 12 and impact protection layer 38.

[0034] In one or more embodiments, impact protection layer 38 includes one or more recessed sections 41. In such embodiments, the recessed sections 41 leave interior surface 36 of outer shell 20 open or accessible to a user. In other words, there is no impact protection layer 38 between outer shell and the user in the locations where the recessed section(s) 41 are positioned.

[0035] Suspension system 14 includes one or more post(s) 40 extending from headband portion 17. In various specific embodiment, suspension system 14 includes padding 44 along a portion of headband portion 17 and/or post 40. Each post 40 includes an aperture 42 extending through post 40. In one or more specific embodiments, suspension system 14 includes two posts 40 and each post 40 includes an aperture 42. In specific embodiments, the number of posts 40 is the same as the number of apertures 42. In other embodiments, the suspension system 14 includes a different number of posts 40 and apertures 42 (e.g., four posts 40 and four apertures 42).

[0036] Aperture 42 is configured to engage a protrusion 46 of hard hat 12. In other words, protrusion 46 acts as a snap in a snap fit arrangement between suspension system 14 and outer shell 20 of hard hat 12. In various embodiments, aperture 42 includes a main or center portion 48 and one or more recessed portions 50. Center portion 48 and one or more recessed portions 50 together define a perimeter of aperture 42. In various specific embodiments, center portion 48 includes two recessed portions 50 with a recessed portion 50 positioned on opposing sides of center portion 48.

[0037] In one or more embodiments, hard hat 12 includes one or more protrusion(s) 46 positioned on interior surface 36 of outer shell. The protrusion(s) 46 extends away from or inward from interior surface 36 of outer shell 20. In various specific embodiments, impact protection layer 38 is positioned adjacent to protrusion 46. In various specific embodiments, impact protection layer 38 does not overlap or cover protrusion 46 allowing a user to access protrusion 46. In other words, impact protection layer 38 is positioned and/or shaped such that a user can reach and change suspension system 14. In one or more specific embodiments, protrusion 46 is positioned within recessed section 41 of the impact protection layer. As such, protrusion 46 is uncovered by impact protection layer 38.

[0038] Referring to FIGS. 4-5, details of protrusion 46 are shown, according to an exemplary embodiment. Protrusion 46 includes a body 52 and a ledge 54. Body 52 extends inward from interior surface 36 of outer shell 20. Ledge 54 extends downward (in the orientation shown in FIG. 5) from body 52. In other words, body 52 extends toward the user of hard hat 12 while ledge 54 extends in a different direction, specifically toward the bottom segment 27 of hard hat 12. In one or more embodiments, the ledge 54 extends beyond a lowermost portion of the body 52. Applicant believes the shape of protrusion 46 allows for secure engagement with suspension system 14 and/or post 40 because protrusion 46 resists movement or removal of suspension system 14 after coupling. In other words, when protrusion 46 is engaged with suspension system 14 and/or post 40, ledge 54 resists movement of the suspension system away from the interior surface 36 of hard hat 12.

[0039] Referring to FIGS. 6-7, details of the attachment mechanism between suspension system 14 and hard hat 12 in an assembled position are shown according to an exemplary embodiment. Post 40 and specifically aperture 42 are placed over protrusion 46 to couple suspension system 14 to hard hat 12. In the assembled position, ledge 54 extends over (i.e., overlaps) a portion of post 40 of suspension system 14. In other words, ledge 54 overhangs a portion of post 40. The position of ledge 54 relative to post 40 prevents unwanted removal of suspension system 14. In other words, protrusion 46 and ledge 54 prevent suspension system 14 from detachment due to blocking lateral movement of post 40. If a user pulled suspension system 14 and/or post 40 laterally, protrusion 46 and ledge 54 specifically would act as a barrier.

[0040] Protrusion 46 includes an inward facing surface 55. As shown in FIG. 7, inward facing surface 55 faces away from interior surface 36. In specific embodiments, inward facing surface 55 is the innermost portion or protrusion 46. In contrast to conventional connectors that have openings for screws, buttons, etc., protrusion 46 and in particular inward facing surface 55 does not have an opening or bore. In one or more embodiments, inward facing surface 55 is uninterrupted or continuous surface.

[0041] Referring to FIGS. 8-10, details of removal of suspension system 14 from outer shell 20 are shown according to an exemplary embodiment. In various embodiments, hard hat system 10 requires a tool, such as tool 70 for removal of suspension system 14. In various embodiments, tool 70 includes a handle 72, a shaft 74, and a head 76. In specific embodiments, head 76 extends in a perpendicular orientation from shaft 74. In various embodiments, tool 70 is a pick. In specific embodiments, tool 70 is a 90 degree pick.

[0042] As shown in FIGS. 9-10, tool 70 can be inserted between post 40 and interior surface 36 of outer shell 20. Once head 76 is positioned between post 40 and outer shell 20, a user twists tool 70 to access aperture 42. After head 76 is engaged with aperture 42, the user can pull tool 70 inward (i.e., away from interior surface 36) and remove post 40 from the assembled position where protrusion 46 is engaged with post 40.

[0043] Referring to FIGS. 11-12, details of a hard hat system 110 with a suspension system 114 are shown according to another exemplary embodiment. Hard hat system 110 includes hard hat 12 and suspension system 114. Suspension system 114 is substantially the same as suspension system 14 except for the differences discussed herein.

[0044] Suspension system 114 includes a headband portion 117 with one or more posts 140 extending from headband portion 117. Each post 140 includes an aperture 142 configured to engage with a snap or protrusion (see e.g., FIG. 12) extending from an interior surface of the hard hat to secure suspension system 114 to hard hat 12. In various embodiments, aperture 142 includes a main or center portion 148 and one or more recessed portions 150 extending from center portion 148. Center portion 148 and one or more recessed portions 150 together define a perimeter of aperture 142. In various specific embodiments, center portion 148 includes two recessed portions 150 with a recessed portion 150 positioned on opposing sides of center portion 148.

[0045] In various embodiments, post 140 includes a raised edge 152 extending around at least a portion of aperture 142. Raised edge 152 extends inward or away from interior surface 36 when suspension system 114 is coupled to hard hat 12. In other words, raised edge 152 includes a larger dimension or height than other sections of post 140. In various embodiments, post 140 includes one or more side apertures 154 extending through post 140. In specific embodiments, post 140 includes a pair of side apertures 154 with an aperture 142 positioned between the side apertures 154.

[0046] Referring to FIG. 13, details of a suspension system 214 are shown according to another exemplary embodiment. Suspension system 214 is substantially the same as suspension systems 14, 114 except for the differences discussed herein. Suspension system 214 can be utilized with hard hats such as hard hat 12.

[0047] Suspension system 214 includes a headband portion 217 with one or more posts 240 extending from headband portion 217. Each post 240 includes an aperture 242 configured to engage with a snap or protrusion (see e.g., FIGS. 6 and 12) extending from an interior surface of the hard hat to secure suspension system 214 to the hard hat. In various embodiments, aperture 242 includes a main or center portion 248 and one or more recessed portions 250 extending from center portion 248.

[0048] Center portion 248 and one or more recessed portions 250 together define a perimeter of aperture 242. In various specific embodiments, center portion 248 includes four recessed portions 250 with a recessed portion 250 positioned around center portion 248. In a specific embodiment, center portion 248 and recessed portions 250 together form an X-shaped aperture 242.

[0049] It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

[0050] Further modifications and alternative embodiments of various aspects of the disclosure will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosure.

[0051] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article a is intended to include one or more component or element, and is not intended to be construed as meaning only one.

[0052] For purposes of this disclosure, the term coupled means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. As used herein, rigidly coupled refers to two components being coupled in a manner such that the components move together in a fixed positional relationship when acted upon by a force.

[0053] While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.

[0054] In various exemplary embodiments, the relative dimensions, including angles, lengths and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description.